Contractor\'s Tender

The DoDgy BroThers sTainless sTeel FaBricaTors To The sTars

Tender Submission Tender Evaluation: Shonk & D'Shonk Industries Client: Red Heeler Biodiesel Project:1000L Biodiesel Batch Reactor Date: 08/09/2015 Revision: C

Harpo Dodgy Chicko Dodgy

Groucho Dodgy Zeppo Dodgy

The Dodgy Brothers Fabricators Rd., Wagga Wagga Ph: (02) 1234 9876

Executive summary This tender has been in written by The Dodgy Brothers in response to the requirements of the designing company Shonk & D’Shonk’s, which is acting on the behalf of the client Red Heeler Biodiesel. The purpose of this tender is to demonstrate to Shonk & D’Shonk that The Dodgy Brothers’ understanding of the design and construction method makes it the most suitable company to construct the Biodiesel Batch Reactor for them. Among the main reasons why this tender should be considered favourably is that the tender evaluation criteria set out by Shonk & D’Shonk have been accurately addressed. The designers require that the contracting company has staff experienced in stainless steel welding as well as boilermakers with superior knowledge of welding pressure vessels. The Dodgy brothers have provided evidence that they have built two significant stainless steel constructions, namely a commercial kitchen and chemical plant which are examples of how proficient the staff is at welding stainless steel as well as fabricating pressure vessels. In addition, The Dodgy Brothers possesses current accreditation for building thin-walled medium pressure vessel accreditation from The National Board of Boiler and Pressure Vessel Inspectors. This satisfies the tender evaluation criteria which requires current certification to an appropriate quality standard. Third, the designers can rest assured that The Dodgy Brothers have the relevant capabilities as required by them in the tender evaluation criteria.. Therefore, The Dodgy Brothers not only maintain a core staff of highly skilled and experienced staff , such the head boiler maker Mr Kalashkinov and the head tester, Ms Enola Gay, but also a hiring policy which ensures that newly hired staff are trained to the same level. In addition, the company possesses state-of-the-art equipment to enable bending, grinding, finishing and welding to enable the construction of the reactor. Summary of how the other criteria are addressed (always remember to relate this to the individual criteria, as has been done above) The Dodgy Brothers are proud of their staff, capabilities and reputation and would like to assure Shonk & D’Shonk that a reactor of the highest standard will be delivered within the promised time-frame.

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Table of Contents 1.0 Introduction...................................................................................................................................1 2.0 Design Package Review................................................................................................................1 2.1 Understanding Of Design........................................................................................................1 2.2 Client Brief Compliance..........................................................................................................1 2.3 Concerns And Solutions...........................................................................................................2 3.0 Criteria...........................................................................................................................................2 3.1 Experience...............................................................................................................................2 3.2 Certification.............................................................................................................................3 3.3 Capability.................................................................................................................................3 3.4 (….)..........................................................................................................................................4 3.5 (…)...........................................................................................................................................4 3.6 (..).............................................................................................................................................4 3.7 (.)..............................................................................................................................................4 4.0 Appendix A.1 – Light Stainless Fabrication..................................................................................6 5.0 Appendix A.2 – Heavy Stainless Fabrication................................................................................7 6.0 Appendix A.3 – HR Policies..........................................................................................................8 7.0 Appendix B.1 – Pressure Vessel Accreditation..............................................................................9 8.0 Appendix C.1 – Resume of Mr Mikhail Kalashnikov.................................................................10 9.0 Appendix C.2 – Resume of Ms Enola Gay..................................................................................11 10.0 Appendix D.1 – Plate Bending Facilities..................................................................................12 11.0 Appendix D.2 – Drilling Facilities.............................................................................................13 12.0 Appendix D.3 – Welding Facilities............................................................................................14 13.0 Appendix D.4 – Testing Facilities.............................................................................................15

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1.0 Introduction This document contains The Dodgy Brothers tender submission for the construction of Red Heeler Biodiesel's 1000L Biodiesel Batch Reactor. This document has been written in response to the criteria as defined by the Shonk & D'Shonk Industries document rhb01_tec_1.3.2, developed on behalf of Red Heeler Biodiesel.

2.0 Design Package Review A design review has been performed to ensure that the Dodgy Brothers has a full and complete understanding of the project.

2.1 Understanding Of Design The design is based upon the transestification of lipids and alcohol in the presence of a base catalyst to produce a methyl ester suitable for use in diesel engines. A batch processing reactor is used. The reaction materials must be heated to at least 100ºC, but as methanol boils at 64ºC, the process is acting under pressure. The reactor as currently designed will be suitable for purpose. The material of construction is a grade of stainless steel, 304, that is resistant to both acids and bases. The process temperature, 80ºC, is well within the capabilities of the steel, with no significant loss of material strength occurring until at least 250ºC………...

2.2 Client Brief Compliance The Client brief calls for a design that is capable of processing 1000L of material at a time with a freeboard of 250mm. The dimensions of the design, Table 1, indeed provide a reaction volume of 1000L with the appropriate freeboard of 250mm Table 1: Reactor Dimensions Dimension

Value (mm)

Diameter

900

Cylinder total height

1650

Freeboard

250

Material height

1400

Cone diameter

900

Cone height

515

Contained volume

1000L

The brief calls for an operating range of 10ºC – 100ºC which is easily……….

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2.3 Concerns And Solutions The Dodgy Brothers has 2 concerns relating to the design of the reactor. The first relates to the stability of the structure. It is a concern that both the current hold down plates and associated Dynabolts are insufficient. It is recommended that the hold down plate thickness be increased from the present 4mm to 6mm. In conjunction with this, the existing 8mm diameter holes should be enlarged to 10mm and that the dynabolts likewise be increased in diameter. They should also be lengthened from 100mm to 150mm. The second concern is that ………...

3.0 Criteria Please note that in answering this tender, the criteria have been listed in italics and then the Dodgy Brothers response follows in normal text.

3.1 Experience Experience welding stainless steel: Due to the chemical composition of stainless steels, a higher skill/knowledge level than that required for the welding of plain carbon steels is required. The successful tenderer will have staff on hand who have a proven track record in the welding of stainless steel, and more specifically plate material up to a thickness of 5mm. The Dodgy Brothers are a company that specialises in stainless steel fabrication. To this end we have worked on projects ranging from commercial kitchens to chemical plants. In Appendix A two samples of our work can be seen. The first, Appendix A.1 is of a commercial kitchen that was fabricated for an English chef by the name of Jamie Oliver. He can be contacted on +44 1234 9876 to vouch for the standard of our work. The second sample, Appendix A.2, is of a piece of chemical plant that we have fabricated for Dr Timothy Leary. He can be contacted on 0499 9876 5432 to vouch for the standard of our work. As you can see in both samples, our staff have successfully undertaken large amounts of stainless steel welding. As our main business is stainless steel fabrication, it is a corporate requirement that all fabrication staff be trained in stainless steel handling. Appendix A.3 is an extract from our HR guidelines for the hiring of fabrication staff. Experience fabricating pressure vessels: The failure of a weld in a pressure vessel can have catastrophic results, such as an explosion. To this end, the successful tenderer will have on staff boilermakers with experience in welding pressure vessels that operate at up to 500kPa. As a part of The Dodgy Brothers business is the fabrication of chemical plant, our boilermakers and welding inspectors are well aware of the skills required to manufacture pressure vessels. As can be seen in Appendix A.2, we have fabricated large pieces of plant before, in fact the piece in question had a test pressure of 2.0MPa, 4 times your requirements.

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3.2 Certification Currently certified to a relevant quality standard, such as ISO 9000 1: The obtaining of a relevant quality accreditation indicates to the client, Red Heeler Biodiesel, that the tenderer holds quality, responsibility and repeatability in high regard. Accreditation to ISO 9000 or a suitable equivalent as published by a recognised national standards body, such as Standards Australia, or by a relevant industry body, such as Engineers Australia, American Society of Mechanical Engineers or The National Board of Boiler and Pressure Vessel Inspectors would be expected. Please refer to Appendix B.1 where a copy of The Dodgy Brothers accreditation certificate for The National Board of Boiler and Pressure Vessel Inspectors “Schedule 4, Thin Walled Medium Pressure Vessels Accreditation” can be found.

3.3 Capability Sufficient staff to handle the project: The tenderer must be able to show that they have sufficient, suitably trained, staff to complete the project. These staff must be allocated to the project for a minimum of 75% of their billable hours. Dodgy Brothers maintains a core staff who have much experience in the fabrication of stainless steel pressure vessels. Resumes for our head boilermaker, Mr Mikhail Kalashnikov, and head quality tester, Ms Enola Gay, are attached in Appendix C.1,2. Their subordinates, due to our hiring policy, Appendix A.3, are also well trained in stainless steel operations. We also maintain strong links to sub-contractors who are skilled to the same level as our staff if there should be a need for extra staff. We can arrange for additional resumes if need be. Appropriate workshop equipment suitable for welding of stainless steel plate, plate rolling – up to 5mm thickness and pressure testing of vessels. The tenderer must have appropriate equipment for the arc welding of stainless steel plate, such as welding stations, rods, inert gases etc. As the reactor is tubular, the tenderer must be able to show the capability to roll plate, of up to 5mm thickness, into a tubular form. The reactor operates under pressure so the tenderer must be able to pressure test the vessel, upon completion, to show conformance with the design. Red Heeler Biodiesel is prepared to accept the tenderer showing a strong relationship with a subcontractor for the rolling and pressure testing. As we have shown in Appendix A.1 & A.2, we have fabricated a variety of stainless steel items. To successfully fabricate these items, we have done all of the bending, grinding, finishing, welding etc. in house. To this end, we have available:     1

1 of Big Bendy Jigga 5000 sheet metal bending apparatus, Appendix D.1 1 of Puts Holes in Things Drill Press, Appendix D.2 5 of Bright Sparky Thing MIG welding units, Appendix D.3 1 of X-Ray Thingy weld inspection unit, Appendix D.4

http://www.iso.org/iso/home/standards/management-standards/iso_9000.htm

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All pressure vessel testing is handled internally by ourselves as we are suitably certified, Appendix B.1

3.4 (….)

3.5 (…)

3.6 (..)

3.7 (.)

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Appendices

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4.0 Appendix A.1 – Light Stainless Fabrication A commercial kitchen that was fabricated and installed for a Mr Jamie Oliver.

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5.0 Appendix A.2 – Heavy Stainless Fabrication A large process vessel that was fabricated, tested and installed for a Dr Timothy Leary.

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6.0 Appendix A.3 – HR Policies The following is an extract from the current HR guidelines for the hiring of fabrication and testing/quality staff …. …. …. 4.3: All staff that are associated with the fabrication of stainless steel will hold at a minimum the following qualifications:  Trades: Relevant certification to the highest level that TAFE offers with respect to stainless steel fabrication.  Professional: A degree in a relevant branch of Engineering. 4.4: All experienced staff that are associated with the fabrication of stainless steel will have at least 3 years experience. Apprentices will be apprenticed to an experienced staff member as required by TAFE. Graduate Engineers will be mentored/supervised by professional staff with a minimum of 10 years experience and who hold the certification of CPEng. …. …. ….

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7.0 Appendix B.1 – Pressure Vessel Accreditation Accreditation for pressure vessel testing as issued by The National Board of Boiler and Pressure Vessel Inspectors.

The National Board of Boiler and Pressure Vessel Inspectors This is to certify that

The Dodgy Brothers Know what they are doing when it comes to

Schedule 4, Thin Walled Medium Pressure Vessels Accreditation 2014 B.L. Willard Accreditation Manager

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8.0 Appendix C.1 – Resume of Mr Mikhail Kalashnikov Resume for Mr Mikhail Kalashnikov Current Position: …... …... Previous Experience: …... …... …... …... Education: ….. …..

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9.0 Appendix C.2 – Resume of Ms Enola Gay Resume for Ms Enola Gay Current Position: …... …... Previous Experience: …... …... …... …... Education: ….. …..

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10.0

Appendix D.1 – Plate Bending Facilities

Plate bending facilities available to The Dodgy Brothers.

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11.0 Appendix D.2 – Drilling Facilities

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12.0

Appendix D.3 – Welding Facilities

Welding facilities available to The Dodgy Brothers.

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13.0

Appendix D.4 – Testing Facilities

X-Ray, Non Destructive Testing, Facilities available to The Dodgy Brothers.

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